Spill resistant disposable cup

ABSTRACT

A spill resistant disposable cup is comprised of a sheet of flexible material rolled into a cylindrical or frustoconical shape sealed at its edges and with a sealed bottom. The cup has at least three tabs that can be folded down in an overlapping manner to close the top of the cup. The tabs contain an interlocking mechanism to lock folded tabs in place. Two of the tabs are spaced apart to define a gap and a drinking opening when the tabs are folded down. The tabs can be shaped to form an internal sealing edge that provides resistance from leakage and spills if the cup is tipped when full.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from U.S. Provisional patent application No. 62/557,441, filed on Sep. 12, 2017, the entire contents of which is expressly incorporated by reference.

FIELD OF THE INVENTION

The invention relates to containers with integrated folding tops, and more particularly, spill-resistant drinking containers that can be made of conventional coffee cup paper.

BACKGROUND

Disposable paper cups are commonly used. However, most paper cups are open-topped and so can easily be spilled. The conventional solution is to add a separate lid that can be snapped onto the cup. This has several drawbacks. A merchant needs to stock both cups and lids. The lid does not always stay in place and if not fully pressed into place may provide a false sense of security from spills. In addition, the lids are typically plastic and so create additional waste which needs to be disposed of.

Various attempts have been made to provide cups that have integral tops that can be folded over to close the cup. However, these attempts fail to provide a suitable spill-resistant enclosure and have additional flaws.

For example, U.S. Pat. No. 7,681,784 discloses a cup-like container with an origami-styled foldable closure system. The user can fold down the sides of the cup in an interlocking manner. However, the folding pattern is unintuitive to use and can be difficult to implement because all of folds need to be made simultaneously. In addition, once folded, the container cannot be drunk out of. In order to drink from the cup, the user must undo the previous folds and open the cup fully. This makes the cup difficult for the user to use as well as inconvenient to drink from.

U.S. Pat. No. 8,864,016 discloses a foldable cup with an integrated lid. This cup has two overlapping pieces of flexible material that can be folded in a specific pattern to form a narrow-topped cup with an extended spout from which the user can drink. The cup requires a strip of adhesive to keep the top layer secured to the cup. When the user adds extras to the beverage such as sugar, cream, etc., the user must peel off the adhesive piece in order to open the cup. That adhesive piece must be reapplied onto the cup to close it once more. If the adhesive fails or weakens, the cup may not close or may pop open suddenly spilling liquid on the user. Likewise, if the cup is accidentally dropped, the adhesive may release causing the liquid inside to spill. The drinking portion of the cup is also in the form of an elongated spout which may be awkward to drink from. In addition, the spout shape can easily be crushed between the lips or teeth of a person drinking from the cup, making it easy to inadvertently squeeze the spout closed and block liquid from being poured out.

SUMMARY

A spill-resistant foldable and disposable drinking cup is presented which addresses the problems of the prior art and provides other advantages. The cup has three or more integral tabs that can be folded over each other to close the cup. The tabs can easily and repeatedly be folded down by a user in order to close the cup and unfolded to open the cup. The folding design includes an opening that allows a user to easily drink from the cup when it is closed. The tabs can be configured so that when the cup is closed, the tabs interact with the side walls of the cup to help seal the cup and make it spill resistant if the cup is tipped over or dropped.

The folded tabs can be locked in place using various interlocking mechanisms including a tongue-in-slot configuration. The body of the cup can be formed using an integral sheet of flexible, relatively stiff material. The sheet is rolled into a cylindrical or frustoconical shape and the edges connected to each other at a seam line. In one configuration, the sheet is configured so that the seam will run through the tongue, stiffening it to provide a more secure closure.

The sheet material can be coated on one side with a water resistant lining. An extension of the sheet material can be provided in the area of the drinking opening and that can be folded down to form a drinking rim that makes drinking from the cup more sanitary and also helps prevent the outside of the cup from getting soggy.

The cup can be provided with an integral handle and a textured surface can be provided on at least part of the cup exterior to make the cup easier to hold.

Further features of the present invention will be apparent from the following description of exemplary embodiments and with reference to the attached drawings.

BRIEF DESCRIPTION OF THE FIGURES

These and other features and advantages of the invention, as well as structure and operation of various implementations of the invention, are disclosed in detail below with references to the accompanying drawings:

FIG. 1 is a perspective view of a cup according to an embodiment of the invention in an assembled but unfolded state’;

FIG. 2 is a sheet of material used to form a cup as in FIG. 1;

FIG. 3 is a perspective view of the cup of FIG. 1 with two of the tabs folded down;

FIG. 4 is a perspective view of the cup of FIG. 1 in a fully closed position;

FIG. 5 is a top view of the cup of FIG. 1 with two of the tabs folded down;

FIG. 6 is sheet of material for forming a cup according to a further embodiment of the invention; and

FIG. 7 is a perspective view of a cup formed using a sheet of FIG. 6

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1-5 show an embodiment of a foldable drinking cup 10 according to various aspects of the invention. The cup 10 has a body 12 with a top 14 and a bottom 16. The assembled cup has a central axis 18 and, in its unfolded configuration, is generally cylindrical or frustoconical in shape, with the specific shape dependent on the circumference of the cup 10 at its top 14 relative to its bottom 16.

The cup can be formed from an integral sheet 20 as shown in FIG. 2. Sheet 20 comprises a relatively stiff yet flexible material of type suitable for liquids. In one embodiment, sheet 20 is plastic or wax lined paper of the type used to make disposable coffee cups. Other materials can also be used, such as plastic or composite materials.

Sheet 20 has left and right sides 22 a, 22 b. During manufacturing, the sheet 20 is curled so that sides 22 a, 22 b overlap. The overlapping surfaces can be permanently connected to each other using a conventional food-safe adhesive such as a silicone-based adhesive or cyanoacrylate. Alternative joining methods can also be used, including paper fusion by high compression pressure with paper edged being overlapped or fold into each other. The overlapping area forms a seam 24. The bottom 16 of the cup, which can be a disk made of the same material as sheet 20, can be attached to the cup using standard techniques applicable to the manufacture of conventional paper drinking cups, such as by crimping the bottom of the sheet 20 and the outer edge of disk 16 together, to seal the bottom of the cup so it can hold liquids without leaking.

The assembled cup has a plurality of circumferentially arranged tabs extending from the top portion 14 of the body 12, including at least first second and third tabs 30, 32, and 34. The sheet 20 can be formed so the seam falls at any point along the periphery of the cup. In one configuration, the seam 24 extends through one of the tabs. In the illustrated embodiment, seam 24 extends through the third tab 34. Thus in the unrolled sheet 20 shown in FIG. 2, tab 34 is comprised of overlapping tab portions 34′ and 34″. As explained further below, seam 24 advantageously stiffens the tab 34. Although three tabs are shown, alternative embodiments can have more than three tabs.

Each of tabs is foldable towards the central axis 18 along a respective fold line and the tabs at least partially overlap when they folded inward along the respective fold lines. The tabs each have a respective periphery with periphery edge regions extending from the tab's fold line. At least two adjacent tabs are spaced apart from each other at their adjacent edge regions to form an intervening gap.

In the illustrated embodiment, first tab 30 is foldable towards axis 18 along a fold line 30 a. Tab 30 has a periphery 31 with first and second edge regions 31 a, 31 b adjacent opposite ends of the fold line 30 a. Likewise, tab 32 has a periphery 33 with first and second edge regions 33 a, 33 b adjacent opposite ends of the fold line 32 a. The first edge regions 31 a, 33 a of first and second tabs 30, 32 are adjacent to each other but spaced apart at their respective fold lines to form a gap 36 with an edge 37 between the respective fold lines 30 a, 32 a of the tabs 30, 32.

As shown in FIG. 3, the first and second tabs 30, 32 are configured so that when the first and second flaps are folded in an overlapping manner a portion of the gap 36 remains open. The opening is bounded by the edge 37 and at least part of the first edge regions 31 a and 33 a of the first and second tabs 30, 32. The opening forms a drinking opening through which liquid contained within the cup can pass. The size of the gap and shape of the tab edge regions 31 a, 33 a define the overall size of the drinking opening. Different sizes can be provided according to the type and/or consistency of drink to be contained. For example, the drinking opening for a cup designed to hold a thick soup would be larger than one designed to hold coffee. While the gap 36 discussed herein is formed between the first and second tabs and the tongue is on the third tab, the gap 36 can be positioned between any two adjacent tabs.

The third tab 34 can be folded inward in an overlapping manner with the other tabs to close the top of the cup. The tabs 30, 32, 34, are configured with a closure mechanism that can be used to keep the tabs in a folded position. Various interlocking configurations can be used. In one configuration, a tongue-in-slot mechanism is used wherein one tab has a tongue that can be inserted into an aperture in at least one other tab to hold the tabs together.

The tabs can have varying shapes. For example, the first and second tabs 30, 32 shown in FIG. 2 are roughly triangular in shape with a cut-in portion in the gap region whereas the first and second tabs in FIG. 1 have a more trapezoidal shape. In addition, the tabs can have different relative sizes depending on the desired overall shape of the upper portion cup when the tabs are closed. In one embodiment the length of the fold lines 30 a, 32 a for the first and second tabs are substantially the same size. This will give the cup top a generally triangular shape when the flaps are folded. In a more specific embodiment, the length of the fold line 34 a for the third tab is the length of one of the first or second fold lines (30 a or 32 a) plus half the length of the drinking edge 37. This will give the cup top a generally equilateral triangle shape and for appropriately shaped fold lines, a Reuleaux triangle shape.

In one embodiment, the first tab 30 includes a first elongated aperture 40 and the second tab 32 has a second elongated aperture 42. The apertures 40, 42 are substantially the same size and shape and are positioned so that they are aligned with each other when the first and second tabs 30, 32 are folded in as shown, e.g., in FIG. 4. The third tab 34 has a tongue 44 sized and shaped to fit into the apertures 40, 42 or both when the third tab is folded down and to resist being withdrawn.

In the specifically illustrated embodiment, and with reference to FIG. 5, the tongue 44 has a head 44 a having width A and a neck 44 b having width B which is narrower than A. The width W of the apertures 40, 42 is less than width A but greater than width B. A height H of the apertures is sustainably smaller than C.

In the illustrated embodiment, the tongue shape is symmetrical. Alternatively, different shapes, symmetric or asymmetric, can provided. In the illustrated embodiment, the apertures 40, 42 are positioned on the tabs 30, 32 so that when the tabs 30, 34 are folded down, the overlapping apertures 40, 42 run across the top of the cup and the tongue 44 is generally aligned in perpendicular to the apertures. In alternative configurations, the tongue and aperture could be arranged in different ordination and direction relative the tabs.

As noted above, when the cup is manufactured, there will be a seam 24 where the edges 22 a, 22 b of the sheet 20 overlap and are joined together. While this seam could be positioned anywhere on the first, second and third tab, or in between adjacent tabs, in a particular embodiment, the seam 24 is configured so that it is present in the third tab 24 having the tongue 44 that engages slots in one or more other tabs and more preferably passes through the tongue 44 itself. Advantageously, the seam 24 stiffens the third tab 34 so that the tongue 44 provides a more secure closure.

While a tongue and aperture locking mechanism is shown, different mechanisms using various combinations of tabs with of apertures, hooks, tongues, and other interlocking structures can be used to allow at least two of the tabs to interlock and retain the tabs in the inward folded position.

The width of the tabs on the cup and the length of the associated fold lines can be varied as appropriate based on the number of tabs and the desired cup geometry. In a preferred three-tab embodiment as shown in the figures, the first and second tabs are symmetric and have fold lines that are substantially the same length and are several times longer than the length of the drinking edge 37, such as about 3, 4, or 5 times the length. The fold line 34 a of the third tab 34 can be similarly size. In alternative embodiments, the length of the third fold line 34 a and the width of the third tab 34 can be larger or smaller than that of the other tabs.

According to a further feature, the flaps can be configured so that when the flaps are closed, at least part of the periphery of one or more flaps forms a sealing region against the side of the cup to help prevent liquid from spilling in that area. In a particular configuration, and as best shown in FIG. 5, at least part of the second edge regions 31 b, 33 b of the first and second flabs 30, 32 are configured so that when the first and second flaps 30, 32 are folded down along the respective fold lines 30 a, 32 a, these edge regions 31 b, 33 b cooperate to form a sealing edge region 50 having a generally continuous contour. The sealing edge region 50 is configured so that it is in at least close proximity to the fold line 34 a of the third tab 34 and the second edge regions 31 b, 33 b are shaped so that the sealing edge region 50 has a contour that is substantially the same as the contour of the fold line 34 a of the folded third tab 34 when the third tab is folded down.

More preferably, the sealing edge region 50 is configured so that when the third tab 34 is folded over the first and second tabs 30, 32 and locked into place, e.g., by inserting the tongue 44 into the apertures 40, 42, at least parts, and preferably a majority of, the sealing edge region 50 contacts the side of the cup along the third fold line 34 a. This interaction helps prevent liquid in the cup from flowing out when the cup is tipped. It should be appreciated that before the third tab is folded down, the sealing edge 50 may be further from, and perhaps not touching at all, the third fold line 34 a.

As noted above, the tabs 30, 32, 34 are arranged so that they can be folded inward along respective fold lines 30 a, 32 a, 34 a. To help place the fold lines in advance of actual folding, at least part one or more of the fold lines can be defined by a crease formed in the sheet 20. In the illustrated embodiment, the first tab 30 has a crease 32 b which defines at least part of the fold line 32 a. The second tab 32 has a crease 32 b which defines at least part of the fold line 32 a. Finally the third tab 34 has a crease 34 b which defines at least part of fold line 34 a.

Preferably, and as shown in the figures, for each of the first and second tabs 30, 32, one end of the respective crease 30 b, 32 b is spaced away from a point where the first edge of the respective tab meets the respective fold line, and the second end of the crease is substantially adjacent a point where the second edge of the respective tab meets the respective fold line. In a more specific configuration, creases 30 b and 32 b associated with the first and second tabs extend over about ⅔ of the respective fold line 30 a, 30 b with the fold lines closest to the gap 36 left uncreased. Omitting the crease in the immediate vicinity of the gap 36 allows for a less abrupt fold in the first and second edge regions 31 a, 33 a of the first and second tabs 30, 32 when they folded down, and so a smoother shape of the drinking area.

For the third tab 34, the crease 34 b extends over substantially the entire fold line 34 a. Different configurations are possible with the crease covering more or less of the fold line on the individual tabs.

The creases can be formed in various manners. They can be embossed, debossed, or scored to predefine the fold lines depression and can be formed on the inside or the outside of the body (or both). The creases which define the fold lines can be different shapes. In a particular embodiment, the creases are generally parabolic with ends that rise upwards relative to the bottom of the cup. However, they alternatively can have different shapes, such as being arcuate, or another curve shape, and can be curved upwards or downwards. The crease could also be linear. Multiple, spaced apart creases can also be provided to define each fold line, such as where the creases are dotted or dashed lines.

With reference to FIG. 6, a handle portion for the cup can also be provided. In this embodiment, sheet 20′ has a handle portion 60 extending from one of the sides 22 a, 22 b of the sheet. When the sheet is rolled into a cup, the handle portion 60 will lie generally flat against the cup's outer surface. It can be folded outward by a user to serve as a handle. For example, user can slide their thumb into the ear and avoid holding the hot cup entirely.

To further secure the tabs in place when folded down, a small slot can be provided in one or both of the first and second tabs 30, 32, such as slot 70 and 72 which will allow these tabs to interlock when they are folded over each other, thus providing a more secure closure and also helping to hold the first and second tabs 30, 32 in a folded position until the user can insert the tongue 44 on the third tab 34.

With reference to FIGS. 6 and 7, at least part of the cup surface can also be coated with a textured, ribbed or other surface feature that provides a more secure grip-friendly surface on the cup. In the illustrated embodiment, a series of protruding ribs 90 are formed on the cup and positioned to be in the back of the cup on the opposite side of where the drinking opening is. Other textures, such as raised dots or geometric shapes (circles, squares, hexagons, etc.) can be used as well.

With further reference to FIGS. 6 and 7, the drinking edge 37 can be modified to form an extension finger 80 that extends between the two adjacent tabs. When the cup is used, the finger 80 can be folded down along the outside of the cup to form a rim 82. When the user drinks from the cup, their lips will touch the rim. Because the inside of the cup is layered with a water-proof material, the now outward facing part of the rim will also be coated with the water-proof material and so provide a water resistant region on the exterior of the cup even if the remainder of the cup outside is uncoated. This helps prevent the area of the cup near the drinking opening from getting soggy. In addition, this allows to drink from the cup without their mouth having to touch the main outside surface of the paper cup body entirely. This makes use of the cup more hygienic because the interior of the cup is less likely to be exposed to dirt or other contaminants before use.

The various dimensions of the cup components can be altered to make the cup taller or wider. A hole or slit can be formed in one of the tabs of a suitable size to receive a drinking straw.

Various aspects of the invention have been disclosed and described herein. However, various modifications, additions and alterations may be made by one skilled in the art without departing from the spirit and scope of the invention as defined in the appended claims. 

What is claimed is:
 1. A drinking cup comprising: a body have a top, a bottom, and a central axis a plurality of circumferentially arranged tabs extending from the body including at least first second and third tabs extending from the top of the body, the first, second and third tabs each being foldable towards the central axis along a respective fold line, each tab having a respective periphery having first and second edge regions extending from the respective fold line and along the respective periphery, the first, second and third tabs at least partially overlapping when folded along the respective fold lines; the first edge regions of the first and second tabs being spaced apart at the respective fold lines to form a gap between the first and second fold lines defining a drinking edge; the first and second tabs being configured so that when the first and second flaps are folded in an overlapping manner and the third flap is folded over the first and second flaps, a drinking opening is defined by the drinking edge and at least part of the first edge regions of the first and second tabs.
 2. The cup of claim 1 wherein at least part of the second edge regions of the first and second tabs are configured to form a sealing edge region having a generally continuous contour when the first and second tabs are folded in an overlapping manner, the sealing edge region being in at least close proximity to the fold line of the third tab when the third tab is folded over the first and second tabs, at least a portion of the contour of the sealing edge being substantially the same as a corresponding contour of the fold line of the third tab.
 3. The cup of claim 1, wherein the first tab includes a first elongated aperture and the third tab includes a tongue configured to engage the aperture in the first tab when the first and third tabs are folded.
 4. The cup of claim 3, wherein the second tab includes a second elongated aperture, the first and second apertures positioned to be in at least substantial alignment when the first and second tabs are folded down, the tongue configured to engage the first and second apertures when the first, second, and third tabs are folded.
 5. The cup of claim 1, wherein each fold line has a length, the drinking edge has a length, the length of the fold lines of the first and second tabs being substantially equal to each other and greater than the length of the drinking edge.
 6. The cup of claim 5, wherein the length of the fold line of the third tab is substantially the length of the fold line of the first tab plus half the length of the drinking edge.
 7. The cup of claim 1, further comprising first, second, and third creases associated with the first, second, and third tabs respectively, each crease having a first and second end and predefining at least a portion of the fold line for the respective tab.
 8. The cup of claim 7, wherein each crease is substantially parabolic along its length.
 9. The cup of claim 8, wherein, for each of the first and second tabs, the first end of the crease is spaced away from the drinking edge and the second end of the crease is substantially adjacent a point where the second edge of the respective tab meets the respective fold line.
 10. The cup of claim 1, wherein the body comprises an integral sheet of flexible, relatively stiff material having a seam where first and second body edges are joined together, the seam extending from the bottom to the top.
 11. The cup of claim 10, wherein the first tab includes an elongated aperture and the third tab includes a tongue configured to engage the aperture when the third tab is folded over the first tab, and wherein the seam extends through the third tab and at least part of the tongue.
 12. The cup of claim 4, wherein the first tab has a first notch therein and the second tab has a second notch there, the first and second notches configured so that the first and second tabs can interlock at the first and second notches when the first and second tabs are folded in an overlapping manner.
 13. The cup of claim 10, further comprising a handle region extending from the sheet.
 14. The cup of claim 1, further comprising a finger extending from the drinking edge and into the gap and which can be folded outward from the central axis. 